Method of winding armatures



June 29, 1965 H. w. MOORE METHOD OF WINDING ARMA'I'URES 2 Sheets-Sheet 1Filed Dec. 12. 1958 INVENTOR. H/JEEY M M0055 H/S ATTOENE'YS M 7 2 J mJune 29, 1965 H. w. MOORE 3,191,269

METHOD OF WINDING ARMATURES Filed Dec. 12. less 2 Sheets-Sheet 2- JIE,1Q

INVEN TOR. #42? VH4 MOOET United States Patent 3,191,269 MEET-10D 0FWINDING ARMATURES Harry W. Moore, 5051 Kittridge Road, Dayton, OhioFiled Dec. 12, 1958, Ser. No. 780,150 2 Claims. (Cl. 29155.53)

This invention relates to a method of winding armatures.

When winding commutator type motor, it is necessary to attach the endsof the coils to the commutator segments. Various types of tangs ornotches may be used for attaching the leads of the coils or windings tothe commutator segments. In the particular embodiment shown herein,hook-like tangs have been used. However, other types of tangs could beused. In connecting the ends of the coils or windings to the commutatorsegments, if the commutator segment is aligned with the coil, the leadsare taut when the coils are wound by automatic winding machines. Thesetaut leads prevent the coils from utilizing much of the space adjacentthe armature shaft. In some cases, successive coils are spaced at greatdistance apart, so that a lead extending from one coil is angularlydisposed when extending to the tang and then the lead from the tang isangularly disposed but in the opposite direction from the first lead, tothereby cause the leads to lie close to the armature shaft. However,this method presents problems.

An object of this invention is to provide a method for winding coilswherein the leads from two adjacent coils are hooked over a tangangularly or circumferentially oifset from the coils and the return leador the lead to the succeeding coil is laid in the same slot or a slotadjacent the slot from which the previous coil extends.

Other objects and advantages reside in the construction of parts, thecombination thereof, the method of manufacture and the mode ofoperation, as will become more apparent from the following description.

In the drawings, FIGURE 1 is a perspective view of an armature corehaving leads extending to two tangs, the tangs being offset at asubstantial angle from the slot from which the leads extend.

FEGURE 2 is a perspective view of an armature having the commutatormounted in an apparatus for intermittently shielding the tangs and forintermittently deflecting the lead from the normal winding path, so asto hook over or engage a tang on the commutator.

FIGURE 3 is another perspective view similar to FIG- 'URE 2, wherein theshield has been retracted from the tangs and the deflecting means is inthe process of hooking the wire on a tang.

FIGURE 4 illustrates a series of coils wound progressively in aclockwise direction, as viewed from the bottom of FIGURE 4, wherein thecoils trail the position of the leads.

FIGURE 5 discloses a series of coils wound progressively in acounterclockwise direction, as viewed from the bottom of FIGURE 5,wherein the coils lead the position of the leads.

FIGURE 6 discloses a series of coils wound progressively in a clockwisedirection, as viewed from the bottom of FIGURE 6, wherein the coils leadthe position of the leads.

FIGURES 7A, 7B, 7C and 7D illustrate successive positions of theapparatus used in hooking the leads on the tangs when winding coils likethose shown in FIGURE 4 and FIGURE 6.

FIGURES 8A, 8B, 8C and 8D disclose successive positions of the apparatusused in hooking the leads on the tangs when winding coils like thoseshown in FIGURE 5.

Referring to the drawings, the reference numeral 10 is used to designatebroadly an armature provided with a radially slotted armature core 11mounted upon an armature shaft 14 supporting the commutator 16 providedwith a plurality of circumferentially spaced commutator segments 18,each provided with a hook-shaped tang 24 the hook being directed in adirection away from the core. The armature core 11 has a plurality ofcircumferentially spaced teeth 12 extending radially and outwardlybetween the radial slots. The shaft 14 supports tubular members 22 ofinsulating material. Furthermore, a tubular sleeve 24 of insulatingmaterial is positioned between the armature core 11 and the commutator16. Although the tangs have been shown as integral with the commutatorsegments, these tangs could be integral with separate pieces abuttingthe sides of the commutator segments. These pieces may be provided withrisers which may be hook-shaped for supporting a lead. Instead of usingtangs, slots in the segments for receiving the segments could be used,the leads being welded or soldered to the slots as the armature is beingwound. In that event, one of the electrodes of the electric welder (notshown) could replace the hook and the other electrode could engage theslot directly above the lead, so that upon the electrodes beingenergized, the leads would then be welded to the slot.

Bitferent types or arrangements of windings have been illustratedschematically in FIGURES 4, 5 and 6. These have been shown merely forthe purpose of illustration, in that numerous modifications of windingsare adaptable for use with the method and apparatus for securing theleads at the ends of the coils to the tangs of the commutator.

In the schematic winding diagram shown in FIGURE 4, a lead or wire 30enters a slot located between the armature core teeth 12a and 12b. Theloop 30a in the lead -30 extends over a tang 20. This tang 20 iscircumferentially offset from the slot through which the lead wiresterminating in loop 36a project. Since FIGURE 4 is diagrammatic, thetang 20 is illustrated as angularly offset, rather thancircumferentially oifset, from the aforementioned slot. The lead extendsfrom the tang 20 down through the same slot between the teeth 12a and12b and then it is hooked around the tooth 1212, one side of the coilbeing located between the teeth 12b and and the other side of the coilin the slot located between the teeth 12d and He. The coil has beenillustrated by a single winding, whereas, in reality, the coil mayconsist of any number of windings or layers, as for example, ten ortwelve, more or less. The lead 3012 extends to another tang 20 andreturns through the same slot hooked around a tooth 12c for winding thesucceeding coil. The winding of the coils progresses toward the right,as viewed in FIGURE 4. Each coil is located to the left of the end leadthereof.

In the diagram shown in FIGURE 5, the wire or lead 32 is first hooked ona tang 20, then it extends to the slot found between the teeth 12 and12g. The coil 32a extends around three teeth. The number of teeth is amatter of choice. The end terminal 32b is hooked around the tooth 12gand extends to the tang through the slot located between the teeth 12gand 12h. In this embodiment the final lead of a coil advances to a slotsucceeding the slot containing the coil before advancing to the tang.

In the embodiment shown in FIGURE 6, the direction of the coils withrespect to the leads is reversed from that shown in FIGURE 4. It isbelieved that the wiring diagram in FIGURE 6 is self-explanatory.

The apparatus used in hooking the leads on the tangs has beenillustrated in FIGURES 2, 3, 7A to 7D and 8A to 8D. This apparatus willnow be described. The apparatus consists of a tubular sleeve or shield40 overlying the commutator segments and abutting the tangs 20, as shownin FIGURE 2. The sleeve 40 may be adjusted from the position shown inFIGURE 2 to the position shown in FIGURE 3, where the end of the sleeve40 has been withdrawn from the tangs to thereby expose the tangs. Thismay be accomplished by connecting a piston rod 42 actuated by a cylinder44 and connected to the tubular sleeve 40, so as to control the positionof the sleeve 40.

Telescopically mounted upon the sleeve 40 is a tubular sleeve 5ftprovided with lead engaging tang extensions 52. In the particularembodiment shown, two lead engaging tang extensions have been shown.This embodiment is used when two fliers are used to wind two separatecoils simultaneously. The sleeve 50 is mounted for rotation upon thesleeve 40 without longitudinal movement of the sleeve 50. A gear ring 54surrounds and is fixedly attached to the sleeve 59. A toothed rack bar56, ctuated by a hydraulic or pneumatic piston 58 is used to rotate thesleeve 50 through successive steps, as may be required. A flier 61),provided with a wire guide or roller 62, is used in winding the coils.Fliers of this type are used in coil winding machines, as illustrated inthe Moore Patent No. 2,627,379. Instead of using hydraulic cylinders toactuate the sleeves 49 and 50, electromagnets or any other suitabledriving mechanism may be used within the purview of this invention.

During the winding operation of a coil, the tubular sleeve 40 abuts thetangs 21 so as to provide a shield preventing the wire or leads fromengaging any of the tangs during the winding operation. In winding thecoils of the type shown in FIGURES 4 and 6, a series of steps used inthe winding operation is shown in FIGURES 7A to 7D inclusive, which willnow be described.

In FIGURE 7A, the sleeve 50 has been rotated so as to rotate theextension 52 which has caught the lead and advanced it in a positionbetween the tangs 20a and 2%. It is to be noted that the lead 36 islocated above the tang 20a, as viewed in FIGURE 7A. However, the sleeve40 shields the tangs when the extension 52 advances the lead upwardly.When the lead enters the position shown in FIGURE 7A, the sleeve 40 iswithdrawn into the position shown in FIGURE 7B. The lead 30, extendingfrom the extension 52 to the slot in the core 11, then drops intocontact with the segments 18 of the commutator 16 between the tangs 20aand 20b. The sleeve is then reversed, so as to move the extension 52into the position shown in FIGURE to hook the lead or wire under thetang 20a. At this time the sleeve 40 is actuated from the position shownin FIGURE 7C into the position shown in 7D, so as to shield the tangsand hold the lead under the tang 20a, which has been moved by the flierinto some other position in readiness for returning the lead through theslot from whence it came. After the lead has been laid in the slot fromwhence it came, the armature is indexed, so as to advance a succeedingpair of slots into winding position.

This series of operations is repeated after the winding of each coilthat is wound upon the armature core until the armature core has beencompletely wound. The lead of the first 'coil and the lead of the lastcoil are hooked under a tang. The armature is then removed from thefixture or apparatus for winding the coils and moved to a welder whereall of the tangs are welded to the leads either simultaneously or inseriatim, as the case may be.

In Winding the coils shown in FIGURE 5, it is necessary to reverse thedirection of the lead with respect to the tangs of the commutatorsegments. The successive steps of the apparatus used in winding coilslike those shown in FIGURE 5, are shown in FIGURES 8A to 8D. When a coilhas been wound and the lead is in the position on the armature coreopposite the commutator, as shown in FIGURE 5, the armature is indexed,so that the lead from the first coil 32a extends up between the teeth12g and 12h efore advancing to the tang. Then the extension 52 is movedfrom inoperative position to operative position, as shown in FIGURE 8A.The shield 49 remains in position until the lead is located between hetang 29a (FIGURE 8A) and the tang 29c. The sleeve 44) is then withdrawnfrom shielding position, as shown in FIGURE 8A. The lead extending fromthe extension 52 to the commutator slot, then drops into contact withthe commutator segment. The extension 52 advances upwardly, as shown inFIGURE 83, feeding the lead 30, extending from the commutator slot underthe tang 20a, into the position shown in FIGURE 80. The sleeve 46 isthen advanced into shielding position, holding the lead under the tang26a. The extension 52 and the sleeve 56 are then reversed, so as to movethe extension 52 into inoperative position and the winding of thesucceeeding coil takes place. These steps are repeated until thearmature is completely wound.

Although the preferred embodiment of the device has I been described, itwill be understood that within the purview of this invention variouschanges may be made in the form, details, proportion and arrangement ofparts, the combination thereof and mode of operation, which generallystated consist in a device capable ofcarrying out the objects set forth,as disclosed and defined in the appended claims.

Having thus described my invention, I claim:

I. In a method of winding an armature core fixedly mounted on a shaftupon which a commutator is also fixedly mounted, the armature corehaving a plurality of circumferentially spaced radial slots and thecommutator having a plurality of circumferentially spaced lead receivingtangs, the method including the steps of shielding the tangs by amovable shield overlying a portion of the commutator, placing a coil ina pair of slots, the coil having a Wire lead extending therefromprojecting out of a slot, removing the shield from tang shieldingposition, deflecting the lead extending from the coil into permanentengagement with a selected tang circumferentially offset from said lastmentioned slot, and moving the shield into tang shielding position whileplacing a succeeding coil in another pair of slots.

2. In a method of Winding an armature core fixedly mounted on a shaftupon which a commutator is also fixedly mounted, the armature corehaving a plurality of circumferentially spaced radial slots and thecommutator having a plurality of circumferentially spaced lead receivingtangs, the method including the steps of shielding the tangs by amovable shield overlying a portion of the commutator, Winding a coilhaving side portions lying in a pair of spaced slots and terminating ina wire lead projecting out of a slot, deflecting a portion of said leadafter completion of the winding of the coil into a positioncircumferentially. spaced from said last mentioned slot, removing theshield from tang shielding position, dropping the deflected portion ofsaid lead into permanent engagement with a tang circumferentially spacedfrom said last mentioned slot, again shielding the tangs by moving theshield into tang shielding position, indexing the armature core, windinga succeeding coil terminating in a lead, again deflecting the lead,removing the shield and dropping the lead into engagement with a tang,and

r n J U continuing the steps recited above until all of the coils2,385,619 9/45 Pausset et al. have bean wound. 2,592,631 4/ 50 Nash29l55.53 X 2,535,438 12/50 McCollom 242-13 References Cited by theExaminer 2,627,379 2/53 Moore 242-13 UNITED STATES A T 2,648,792 8/53Wylie 29-l55.54 X 1 3 5 133 4 1 Cumin 31 2 4 2,756,354 7/56 Baron 310-234 1,571,914 2/26 Fletcher 310-264 2,790,191 4/57 Gage 312F2341,742,190 1/30 Apple 29 155.53 21383113 4/59 Bram 2 r213 g i iiii jj 10JOHN F. CAMPBELL, Primary Examiner. 2,306,855 12/42 Allen. MZLTGN O.HIRSHFIELD, WHITMORE A. NILTZ, 2,348,948 5/44 Allen. ARTHUR M. HORTGN,Examiners.

1. IN A METHOD OF WINDING AN ARMATURE CORE FIXEDLY MOUNTED ON A SHAFTUPON WHICH A COMMUTATOR IS ALSO FIXEDLY MOUNTED, THE ARMATURE COREHAVING A PLURALITY OF CIRCUMFERENTIALLY SPACED RADIAL SLOTS AND THECOMMUTATOR HAVING A PLURALITY OF CIRCUMFERENTIALLY SPACED LEAD RECEIVINGTANGS, THE METHOD INCLUDING THE STEPS OF SHIELDING THE TANGS BY AMOVABLE SHIELD OVERLYNG A PORTION OF THE COMMUTATOR, PLACING A COIL IN APAIR OF SLOTS, THE COIL HAVING A WIRE EXTENDING THEREFROM PROJECTING OUTOF A SLOT, REMOVING THE SHIELD FROM TANG SHIELDING POSITION, DEFLECTINGTHE LEAD EXTENDING FROM THE COIL INTO PERMANENT ENGAGEMENT WITH ASELECTED TANG CIRCUMFERENTIALLY OFFSET FROM SAID LAST MENTIONED SLOT,AND MOVING THE SHIELD INTO TANG SHIELDING POSITION WHILE PLACING ASUCCEEDING COIL IN ANOTHER PAIR OF SLOTS.